Process of printing from a composite hectographic form



\ W. S. COCHRAN PROCESS OF PRINTING FROM A COMPOSITE HEGTOGRAPHIG FORM July 8, 1947.

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JUIY'S, 1947. w. s. COCHRAN PROOEss OF PRINTING FROM A COMPOSITE HEOTOGRAPHIO FORM 5 sheetsheet 5 Filed April 1, 194s -EDE NNJEIE? .m -mrm Patented July 8, 1947 PROCESS OF PRINTING FROM A COMPOSITE HECTOGRAPHIC FORM William S. Cochran, Evanston, Ill., assigner to Ditto, Incorporated, Chicago, Ill., a corporation of West Virginia Application April 1, 1943, Serial No. 481,463

2 Claims.

The present invention relates particularly to the scheduling and control of production in a manufacturing plant. It has for its principal purpose the provision of a system of record keeping devices that are particularly applicable to facilitating accurate and continuous control of scheduled orders as they progress through the various manufacturing steps. f

The invention contemplates, as a specific and important feature of the system, a provision of means whereby detailed records of the activities of operators on a particular machine are maintained. These records are maintained in such fashion that operators of more than ordinary ability or less than ordinary ability can be readily located and arrangements can be made to give adequate recognition for good work as well as to nd the work for which a particular operator is best fitted.

The system in its entirety is so arranged that the calculation of individual performance records in no way upsets the maintenance of the standard system. In any production control system it is necessary, of course, to set up standards for the making of a particular part, and these standards must be in such simple form as to enable them to be broken down into machine or bench opera" tions on which individual records of progress can be maintained. The record keeping must be of such nature as not to involve too much paper work on the part of the production force, butv it must also be adequate to supply the necessary information to enable an order for a definite number of manufactured devices to be carried through the manufacturing process with full information at any time as to its progress and with full records to establish the cost of the manufacturing operations when the job is completed.

In order that the system may be more clearly understood, the accompanying drawings show the working devices or forms that are used at the various stages. In connection with these drawings a complete detailed description will be hereinafter given to illustrate their utility in scheduling of production and control of production throughout the manufacturing process.

In the drawings:

Fig. 1 is a plan View of one of the control records described hereinafter as the shop order master;

Fig. 2 illustrates another record or form which will be referred to hereinafter as the-variable master;

Fig. 3 is a plan View of a third record or form referred to hereinafter as a shop order;

Fig. 4 is a plan View of another record or form referred to hereinafter as the standard cost record summary;

Figs. 5, 6 and 7 illustrate in plan View three (Cl. liu-149.4)

` additional forms which are referred to hereinafter, respectively, as the operators card, the job labor card and the daily summary attendance card;

Fig. 8 is a somewhat diagrammatic View showing the application of a plurality of overlapped job labor cards to a duplicating pad;

Fig. 9 is a fragmentary plan View illustrating how the notched cards are arranged in overlapped relation;

Fig. 10 is a plan View, partly broken away, of

the holding device for holding cards in overlappedA relation; and

Fig. 11 is a sectional view on line lI-II of Fig. 10.

AWith the exception of the daily summary attendance card all of the forms carry related information which is placed upon them by a duplicating operation from the shop order master and the variable master forms.

In the preparation of the shop order master the items entered upon this master in copying ink include the part or assembly number and name, the name of the product on which the part or assembly is to be used, individual operation numbers and descriptions in the sequence in which the operations are to be carried out, the type of machine on which operation is to be performed, a time standard established for each operation, and such other special instructions as may iit each operation, such, for example, as tolerances allowed. It will be noted that. the shop order master, in the upper lefthand corner, has a Vacant area of the same size and shape as the variable master sheet shown in Fig. 2. It will also be noted that each operation of a part carries a number. For convenience these numbers are arranged in tens when the shop order master is iirst made up; that is, the first operation is numbered 10, the second 20 and so on. If a new operation has to be inserted between the first and second operation it can then be given a number such as 15. Also, if changes are made in a particular operation such as operation .10 the changed operation can be renumbered, for ex- Y ample, by giving it the number 11. v

Assuming that an order is received which requires the making up of a definite number of parts for which a shop order master has been prepared, a variable master is made up by typing upon the variable master form shown in Fig. 2 the production order number, part number, number of pieces in the lot to be made, the date ordered and the date wanted. This typing is done in hectograph or other copying ink. The variable master is then temporarily attached to the shop order master for the purpose of makingv the rest of the forms that will be needed in following the progress of the order through the shop.

Where the duplicating method used is the mirror script or reverse printing` method the information typed'lonthe shop orderimaster andff on the variable master will be printed incopy'- ing ink on the back in reverse so that the tWo` masters combined can be used in a liquid process duplication to reproduce Fcopiesf Whereltheiff reproduction is to be done by the so-calledfgelat'in'g process the typing is done in copying ink directly upon the face of theformsand torre-f production purposes the form isv rst"impr'essed" upon the gelatin surface after WhichV thecopies to be made can be taken from@thergelatinsurf-V face.

The shop order shownin Fig. 3 is a complete"r reproduction of the shop'order master and variabl'emaster whemtheyar'e combined. In the'A normalproduction control' one copy of the-shop ord'ris' -all that is vnecessary althoughy of` courseH more copies may be made if .they are desired; In Irakirig'copies `fr'omithe combined shop order aridsva'riable masterunit the ormshownfin" Fig.- 4 (standard costre`cord"summary) is: filled out insiii'ienthumbers for its purpose, butin this case"`only"the" informationen the lefthand` half'l of the shop order master, including the column" to`` the right ofthat showing standard hours al# lowed; is"reproduced. The restv ofthe information isblocked out by use of a block-out sheet'orY eliminated byD momentarily folding' the Amaster under along a prescored line l0. An operators card foreach" operation listed upon the `shop orderrriaster isalso made; AA completed oper-A ators vcard''is shown in Fig; 5; It will be noted that this "card carries'all of the-informationv on` the variable master plus the 'heading-of the shop order master` and* theV informationV relating to one-of-fthe' numbered operations.- One card is* prep'ared' for f each operation.

The operation informationV space on theoper'- at'or'scaid` is immediatelybelow the heading'information" which is? common to all operators cards for'theparticular'part. The operation information is;,h`o'vv`ever," individual to the card. The lieadin'ginformation is rst run onA all' the operatorscardsfor"the particular part.' A block-VY outisheetis`used-to'cover the operation'informa'- tioiwhile the cards "are fed to a" duplicating:` machine towhich the master'has been applied.

In 'ordeir'toplace th'efindividual Aoperation information on 'each operators S card va window' type v blcll'outlsheet'is 'used 'Whiclfis ofthe same size as -theoperators card butvvhichY hasa space cutV out ofitfjustibig enough' to expose 'a single line f ofthe operation'information on the master in the'case of direct" duplication by the liquid proc# ess, or,on the gelatin image in the case'of duplie cation byjthe gelatin pad method; By the' use of anwadju's'table guide'on'tliefeed tray of the duplicating. machine andV by shifting the block'- out sheet to expose the next line'oi operation information after each operators card'is fed'to the machine, eachoperatorsI card' isprovided With its individual operation. information.

Nxt the form shownin Fig.:- 6,the job labor card,is prep'aredbyV copyinguponit by a duplication` operation the same information that ist` copieduponthe operators card. However, with the job labor cards it is necessary tohave 'a 'card fori e'a'ch'shift and each operation;y In otherv wordsanfoperation mayextendover two or moreV shifts 'inwhichcasethere' will betwo or'more job labor cardsrfor" each5 operators card.

Als a matter'o convenience'all of the headings' may be placedy ontli'e: job-labor cards when the master is blockedoutto `put theheadings-orr the his 'name and clock number.

4 operators cards. Then When the window blockout`islbeingnsed Vfor a particular 'operators card the job labor` cards for that operation are also Yfed through the duplicating machine before moving the block-out sheet to expose the next lineivofuoperationinformation 0n the master sheet?y Y The job labor cards serve at a later point in the'sy'stem' ais-mastersY for certain information that"is"."l.\andivvritten in hectograph pencil in the last'tvvo lines at the bottom of these cards. Inorder.y to. accomplish this result the job labor cards are made of a paper that will serve this dualpurpose: that is, as a copy sheet to receive the copying ink in the duplicating process and to serve:as-.amastercopyor the information placed thereon by the' hectog-raph pencil.

Wheri'thecomplete" set of" forms hasl been' copied from" 'the i combined" shop order master `r-and variable'niaster'.. the'varablel 'master is remove'dfrom the-ishop"orderrmasterand destroyed'. Thefshopf-order' master however is. usable overi and over again for subsequentproduction'orders' iori"thesanie part.` These shop ordermast'ers are" therefore keptin'l a* masterl le so 'that-for a succeeding production' orde'rit`r is( onlyr necessary' to niake f up aneuf'variablev master and proceed 'as' before forthe'making of the several. records.'

Inether'oper'a'tion of the'-system'; when an oper; v atorfisre'adytocarry outfa certain operation on" hisniachir'e lie-receives from thetime keeper the Aoperatorfsmcard" for tlfiatmacl'iine.A` The time# keep'erfat'the same time records the starting time on the corresponding job labor card.- The bei" andfthe'l dateon hisop'erat'o'rs card and' takes' theicar'd `with 'him .toY the machine. This :operators"cardvremains" at" the Vmachine until" all the required" pieces called'for oni the'A orderv are"'i'in'ish'ed'in` thatY operation. Whe'nathe last piece isf finished the operator then .Workingrupon the orderk returns the operat'ors" card to th'etime- Ifan operator des'not nish' all' of the pieces on. ani-order by quitting `tirneheth'en `marks up thefnumber of pieces he hasfinish'ed'on the'oper'- Y ators card inthe space providedl and leavesthe card attheY machine;

Hereports to the timer-- keeper'thenumber'ofl pieces finished andthe timekeeper posts this number ofpieces on the jobA labor card forthe shift. This job labor card (Fig. 6) is individual to the operator and carries It formsthe direct means" by which operatorsl of'exceptional performance can be picked out. This part ofthe functionv of the job labor cardunit Will'be pointed out'more fullyrh'ereinafter.

If an operatoron asecond or third shift takes upwhere the rstoperator left off herst goes to the timekeeper who punches hisi`n time on the job labor card bearinghisnameand 'clock number: The timekeeper tells the-incoming op- I erator li'ovvV many' pieces remain to be`completed card to the timekeeper who can then see that the next operation, as shown in sequence by the numbers on the operators cards, gets under way. The timekeepers activity is repeated, insofar as recording is concerned, for each succeeding operation. The completed operators cards are kept in an order file by order number so that the le will show at all times how far a lot has progressed.

As job labor cards are completed (punched out) the following calculations will be made. These will be done by the timekeeper if he has time available or by a comptometer operator if he does not have suiiicient time. The calculations and postings will be as follows:

1. Pieces finished multiplied by the standard time per piece to determine the standard hours earned.

2. Actual elapsed time from the clock punching.

3. Operators base rate. The following calculations are examples of those made by the comptometer operator:

1. If the standard hours earned are more than the actual elapsed time the man has earned full bonus and the time earned is calculated by multiplying the standard hours earned by 120% so that the 20% bonus is added. The resulting figure is the time earned and is entered in the space provided under that caption.

2. If the standard hours earned are less than the actual elapsed time the man may or may not have earned a partial bonus. Therefore the calculation is made by adding the standard hours earned and the actual elapsed time and multiplying by 60%.

(a) If the resulting figure is more than the actual elapsed time he has earned a partial bonus and this figure is the time earned and is entered in the space provided under that caption.

(b) If the resulting figure is less than the actual elapsed time he has not earned any bonus and therefore the actual elapsed time is the time earned and is entered in the space provided under that caption.

3. The following calculations are made and posted with hectograph pencil on the job labor card:

(a) Base rate mult-iplied by time earned to determine amount of pay.

(b) Standard cost which is standard per piece multiplied by number of pieces finished.

(c) Any difference between amount of pay and standard cost is a variance and should be classified under the proper caption.

(d) Per cent of performance which is the total time earned divided by the actual elapsed time.

(e) Explanation of the variance, if any.

() Post clock number and operation number on all job labor cards where the percent of performance is more than a predetermined amount above 100% or more than a predetermined amount below 100%.

These completed cards are than sorted by operator and kept until the end of the day when they are posted to the daily summary attendance card as explained later. (After they are posted and balanced any cards where men had a percentage of performance of less than or more than the predetermined percentage bracket will be sorted out and also any cards with Variances caused by makeup or rework will be sorted out. These will be placed in related, overlapped position on a gelatin machine so the bottom lines show and a report will be run off. This report is exceptionally important to the management, as will be later pointed out, yet no rewriting is necessary to get it.) Then the cards will be filed back .with the others and sent to the cost department.

When the job is completed the job labor cards will be sorted by job number by operation, and the following information will be totaled by operation and posted to the standard cost record summary in the cost department:

1. Actual cost (amount of pay).

2. Standard oost.

3. Variances (with amount of each under proper caption).

4. Explanation of variances.

After this information has been posted, the job labor cards will be filed in the sequence in which they are completed, which is by job number and operation.

A supply of daily summary attendance cards (Fig. '7) will be prepared in advance on the addressograph which fills in the mans clock number, name and social security number. There will be one of these used each day by each man and he will punch in, in the morning, and out at night. The timekeeper will place a new card in the clock rack bythe attendance card for each man. each day so that it will be there for the man when he comes in. If he works any overtime it will be punched .in and out on this card too. At the end of the day the timekeeper will remove these cards from the rack and put in a new one for the next day. He will then gure the elapsed time (with one-half hour lunch deducted) and enter this under the clock punchings. This eliminates punching in and out at noon.

Then he will take all the job labor cards for each man each day and will post the following information from each one to the daily summary attendance card:

1. Allowed time earned.

2. Amount of pay earned.

3. Actual time.

After all the job labor cards for that man have been posted the following entries and calculations will be made, using a hectograph pencil to make the entries on the bottom line of the card (see Fig. 7):

1. Total hours earned.

2. Base rate.

3. Total hours earned multiplied by base rate to determine gross earnings which is entered in gross earnings space.

4. Actual hours multiplied by base rate to determine hourly earnings which is entered in hourly earnings space.

5. The diiference between hourly earnings and gross earnings is bonus earnings which is entered in proper space.

6. Divide the hourly earnings by the gross earnings to determine the percent bonus earned.

7. Clock number (and name if necessary) in proper spaces.

Then the cards will be sorted by clock number and a report will be prepared in the same fashion tion the cards.

as the report was prepared from the bottom lines of the job labor cards. The manner of arranging the cards for running the copies on a geiatin machine is to place them in overlapped relation and to align them so that only the section at the bottom of the card which carries total time, base rate, earnings etc. is exposed. This is the section in which the entries have been made in hectograph ink by hectograph pencil or pen. The cards are made of a dual purpose paper capable of serving as a copy sheet and as a master sheet. A group of the cards can be arranged in this staggered relation upon the device shown in Figs. 8 to l1 or merely against a suitable margin bar to hold them in position until they have been brought into Contact with the duplicating pad of a gelatin type duplicating machine. Of course `other suitable means may be used to posi- Since the cards are in part a result of a previous duplicating operation and are in part a duplicating master theyperform a very unusual function in the successful `operation of the system.

Then the cards will be sent to the payroll department for posting to the payroll records. After posting the cards will be led by clock number by day.

If a set up is necessary before an operator can start a job on a machine a job labor card marked Set up will be punched in for him instead of punching him in on the job labor card for that operation. This set up card will show the same information as the regular job labor card. The operator will be given the operators card for that operation and will be told to return and be punched out when he has completed the set up. When he does so and reports the set up completed the timekeeper will remove the set up and job labor card and punch him out on the set up card and in on the job labor card. Then the operator will go back to his machine and start to work.

In case of machine trouble, cleanup work, sharpening tools, changing cutters or any other non-productive work it will be necessary for the operator to report to the timekeeper when he starts on such work so that he can be punched out on the job labor card and in on a card for machine trouble, cleanup work or whatever it is. Whenever this work is nished and he goes back on productive work he must-report to the timekeeper who will punch him oi on Vthe non-productive job and back in on his productive job. It is very important that this be done so that the operator can protect his bonus earnings and to enable the figuring of bonuses daily.

The shop order will be kept with the lot of material through all operations in the shop and will go to final inspection with the material. There the inspector will initial and date it and mark down the number of good pieces nished, scrap pieces finished and total pieces iinished. Then it will go with the material into the storeroom where the storeroom will acknowledge receipt and then the shop order will be removed and sent back to the planning department. Then it will be filed by order number.

The-functioning of the job labor cards as copy receiving units andas masters from which copy can be taken is very important to the system. It is particularly important in making the system useful for investigating and determining the fitness of man for particular work. The information from the job labor cards compared with the information on the bottom lines of the daily summary attendance. cards for the same individual will show which jobs thev man is best at..

what his daily time record is and whether he does better on one type of operation than another. Also to check the standard time allowed for correctness, all of the job labor cards for diierent individuals` doing the same operation can be placed together in overlapped relation and a copy taken to compare the actual time with the allowed time for all operators. There are various other uses to which the dual function of serving as a copy sheet and a master sheet adapts the record cards. It is believed, however, that the examples given are suicient tol indicate the novelty and advantage of the dual function in systems of this character.

Arrangement of the job labor cards in overlapped relation is greatly facilitated if the cards are provided with means at o-ne edge to enable them to be spaced correctly and quickly. VIt will be noted that the job labor card (Fig. 6) is pro:- vided with regularly spaced notches II at one end. Similar notchesY I2 are provided on the operators card and similar' notches I3 are provided on the daily summary attendance card.Y

These notches cooperate With a margin bar 25 (Figs. S-ll provided as an attachment for a duplicating machine.

Figs. 8 to ll inclusive, illustrate the method of assembling cards in overlapped relation and appiying them to a hectograph pad I5 of a duplicating machine. The attachment referred to above comprises a base plate i6 which is adjustably secured to a side frame I'i of the duplicating machine. Two slots IB--IQ areprovided in the plate i6. and they receive two bolts 2l] and 2| which are providedwith nuts V22 and 23. The plate i6 has an upturned flange 24 to which 'an angle bar is fixed. This bar has vertical V- shaped teeth thereon spaced to match the spacing of the notches II, I2 and I3 on the cards. The plate ltV is provided with a combined cover and clamp 2, which is hinged at 2B and 29 to the plate I5. At the edge 3@ of the cover, a rubber or other yielding material channel 3|v is secured to engage cards 32 on the margin bar 2a. Two springs 33 and 34 are connected between the cover 2l and the platte I5 to fonce the cover down. A lifting finger 35 ismo-unted on a rod 3E that is journalled in two bearings 37 and 38 on the plate it. The rod 36 is bent upwardly back of the cover 2 to provide a handle. The cove-r 2'! is cut out vas indicated at 3Q to clear fthe rod when the cover is swung back. on its hinges.

Now in assembling a stack of cards in overlapped relation, the operator can lay one edge of the card on the margin bar and move the cards singly into register with the Jteeth 2S on the margin bar `as the stack is advanced lengthwise of the bar. The series of overlapped cards Will then be gripped by the cover `v2'IF and be pressed down on to the duplicating .pad I5. As mlany copies as may be desired-can be A`made -from the image on the duplicating padr 'that -is made from the lower lines of the job llaborcards and the daily summary attendance cards;` Since the other matter on the cards is `covered Vexcept for the bottom card and since the other matter on the card is either printed in non-duplicating ink or a mere copyltaken from" the original shop order master, theV copying of vthe information writte-n with hectographic pencilis readily done. A single copy sheet can sho-W the performance records of a large number'of men.

It is believed that the 'foregoing description.

will make the nature of my invention and its advantages clear to those skilled in the art.

Having thus described my invention, what I claim as new and desire to secure by Letters Patent is:

1. A duplicating method for job record and like systems which comprises forming a composite master from a permanent reusable master sheet having information thereon in copyable ink and a single use master strip having infomation thereon in copyable ink by covering a predetermined section of the master `sheet with said master strip, producing copies having classifying information thereon from said composite master upon individual composite copy and master sheets, adding new master information comprising information common to a group of like sheets and infomation differing on the individual sheets Aof a group, in hectograph ink to a marginal edge of said last named sheets and reproducing on a single copy sheet the master information on the individual sheets of la group by overlapping them to form a composite master exposing the marginal edge master portion of each sheet.

2. A duplicating method for job record and like systems which comprises forming a composite master from a permanent reusable mas-ter sheet having information thereon in copyable ink and a singleuse master strip having infomation thereon in copyable ink by covering a predetermined section of the master sheet with said master strip, producing copies fromsaid composite master upon individual composite copy and master sheets; adding new master information, comprising information common to a group of like sheets and information diering on the individual sheets of a group in hectograph ink to a marginal edge of said last named sheets and making copies from the combined marginal edges of the individual sheets of a group.

WILLIAM S. COCHRAN.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 2,215,995 Bellack Sept. 24, 1940 2,220,300 Tathwell Nov. 5, 1940 2,060,190 Foster Nov. 10, 1936 2,209,586 Swift July 30, 1940 

